Lincoln Electric IM892-C manual

OPERA TOR’S MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • Copyright © Lincoln Global Inc. PO WER FEED ™ 25M IM892-C March, 2010 For use with machi[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy fo[...]

vi vi T ABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation ..................................................................[...]

A-1 INST ALLA TION A-1 POWER FEED™ 25M TEMPERA TURE RANGE OPERATION: -40°F to 122°F (-40°C to 50°C) STORAGE: -40°F to 185°F (-40°C to 85°C) INPUT VOL T AGE and CURRENT TECHNICAL SPECIFICA TIONS – POWER FEED™ 25M K2536-1, -2, -3 HEIGHT WIDTH DEPTH WEIGHT 14.5 Inches 8.5 Inches 23.5 Inches 35 lbs (368 mm) ( 216 mm) (597 mm) (15.9 kg) Ha[...]

A-2 INST ALLA TION POWER FEED™ 25M A-2 SAFETY PRECAUTIONS ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground[...]

A-3 INST ALLA TION POWER FEED™ 25M A-3 Figure A.3 A A B B C C D D E E A A B B C C D D E E P OWER SOURCE WIRE FEEDER Power Source Pin Function A ArcLink B ArcLink C "67" voltage sense D 40 VDC E Common Wire Feeder Pin Function A ArcLink B ArcLink C "67" voltage sense D 40 VDC E Common A A B B C C D D E E A A B B C C D D E E A A[...]

A-4 INST ALLA TION POWER FEED™ 25M A-4 WELD CABLE SIZE Table A.1 located below are copper cable sizes recommended for different currents and duty cycles. Lengths stipulated are the dis- tance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. COAX[...]

A-5 INST ALLA TION POWER FEED™ 25M A-5 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • K ee p c yl in d er u pr i gh t a nd chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from weld[...]

A-6 INST ALLA TION POWER FEED™ 25M A-6 CHANGING THE DRIVE MOTOR GEAR RA TIO • Turn off input power at the weld - ing power source before installa- tion or changing drive roll and/or wire guides. • Do not touch electrically live parts such as the wire drive or internal wiring. • When feeding with the gun trigger, the electrode and wire drive[...]

A-7 INST ALLA TION POWER FEED™ 25M A-7 WIRE DRIVE CONFIGURA TION (See Figure A-6) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrod[...]

A-8 INST ALLA TION POWER FEED™ 25M A-8 REMOTE SENSE LEAD SPECIFICA TIONS Welding with Multiple Arcs: ( See Figure A.7) Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixtu[...]

A-9 INST ALLA TION A-9 TYPICAL SYSTEM CONFIGURA TIONS Standard Features Arc Performance • Push-Pull ready for welding aluminum with Pulse and Pulse-on-Pulse™ waveforms. • STT™ capable when used with STT™ equipped Power Waves. • Waveform Control Technology™ for welds with good appearance and low spatter, even when weld- ing nickel allo[...]

B-1 OPERA TION POWER FEED™ 25M B-1 • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could remain energized several sec- onds after the welding ceases.. • Do not touch electrically live part or electrode with skin or wet cloth[...]

B-2 OPERA TION B-2 POWER FEED™ 25M DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the cor- rect voltage and amperage base[...]

B-3 OPERA TION B-3 RECOMMENDED PROCESSES • G MA W ( C V, S y ne r g ic C V , P ul s e , S TT ™ , P ow e r, Pulse on Pulse™, Push-Pull) • FCAW • SMAW • GTAW (Lift Start only) • Solid wires .025" to 1/16" • Cored wires .035" to 5/64" • Cored wires .035" to 3/32" when configured for "extra torque&qu[...]

B-4 OPERA TION B-4 POWER FEED™ 25M 1 3 2 5 4 6 9 14 15 16 8 1 1 12 13 10 7 FIGURE B.1 CASE FRONT CONTROLS (CODE 1 1313) (SEE FIGURE B.1) 1. Left DISPLAY window Shows WIRE FEED SPEED or AMPERAGE. 2. Left KNOB Adjusts values in left display. 3. Right Display window Shows VOLTAGE or TRIM. 4. Right Knob Adjusts values in the right display. 5. Status [...]

B-5 OPERA TION B-5 POWER FEED™ 25M FIGURE B.1a CASE FRONT CONTROLS (CODE 11456 and higher) (See Figure B.1a) 1. Left DISPLAY window Shows WIRE FEED SPEED or AMPERAGE. 2. Left KNOB Adjusts values in left display. 3. Status LED Illuminates a steady green when communicating to the power source properly. 4. MSP4 display window Shows detailed welding [...]

B-6 OPERA TION B-6 POWER FEED™ 25M LED condition Steady green Blinking green. Blinking green, fast Blinking green fol- l o w e d b y b l i n k i n g red. Definition System okay. The power source and wire feeder are communicating normally. Occurs during a reset and indicates the power source is identifying each component in the system. This is nor[...]

B-7 OPERA TION B-7 MAKING A WELD WITH W A VEFORM TECHNOLOGY POWER SOURCES The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company a ff e ct t h e r es u lt s o bt a in e d in ap p ly i ng t h es e p ro - [...]

B-8 B-8 POWER FEED™ 25M ST ART OPTIONS END OPTIONS SET SETUP IR PORT CC Stick Soft WA VEFORM CONTROL TECHNOLOGY S t i c k WELD MODE ARC CONTROL I I ARC FORCE (Soft)-10.0 to (Crisp)+10.0 DESCRIPTION START TIME: 0 to 10 seconds FUNCTION If no remote control is installed, this control sets the time for the weld output to ramp up or down from a prese[...]

B-9 OPERA TION B-9 NON-SYNERGIC GMA W AND FCA W WELDING (See Figure B.4) Non-synergic GMAW and FCAW welding mimics the welding controls of traditional welding power sources. Voltage and WFS are set as independent variables. Three non-synergic welding modes are available. Description Mode Used for: GMAW, Standard CV 5 Best for traditional MIG weldin[...]

B-10 OPERA TION B-10 POWER FEED™ 25M 300 25.3 W FS AMPS V OL TS TRIM L ess W FS L ess V olts M ore V olts M ore W FS 250 54 WFS AMPS VOL TS TRIM Less WFS Shorter Arc Longer Arc More WFS ST ART OPTIONS END OPTIONS SET SETUP IR PORT STD CV MIG WA VEFORM CONTROL TECHNOLOGY WELD MODE ARC CONTROL 5 EFFECT / RANGE Postflow Time 0 to 25.0 seconds Crater[...]

B-11 OPERA TION B-11 POWER FEED™ 25M GMA W (MIG) SYNERGIC WELDING Synergic welding allows for easy procedure setting. The WFS and Voltage change together to maintain an optimal arc length. During synergic welding , when the WFS (left) knob is rotated, the voltage is adjusted accordingly to maintain a similar arc length. 6 4 3 2 5 1 FIGURE B.5 K23[...]

B-12 OPERA TION B-12 Synergic CV programs feature an ideal voltage best suited for most procedures. Use this voltage as a starting point and adjust if needed for personal prefer- ences. POWER FEED™ 25M 220 26.4 W FS AMPS VOL TS TRIM Less Deposition S horter Arc Longer Arc More Deposition SYNERGIC CV VOLTAGE DISPLAY When the voltage knob is rotate[...]

B-13 OPERA TION B-13 POWER FEED™ 25M STEEL AND ST AINLESS SYNERGIC GMA W -P (PULSED MIG) WELDING Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applica- tions. During pulse welding, the welding current continuously switches from a low level to a high level and then back again. Each pulse send[...]

B-14 OPERA TION B-14 POWER FEED™ 25M STEEL AND ST AINLESS SYNERGIC GMA W -P (PULSED MIG) WELDING K2368-1 Power Wave ® 355M 1 K2202-1 Power Wave ® 455M K2203-1 Power Wave ® 455M/STT K2230-1 POWER FEED™ 10M, Bench Model K2234-1 POWER FEED™ 10M Dual, Bench Model K2536-1,-2,-3 POWER FEED™ 25M 2 KP1696-xx, Drive Roll Kit, 2 Roll Feeder KP1697[...]

B-15 OPERA TION B-15 POWER FEED™ 25M 220 1.06 WFS AMPS VOL TS TRIM Less D eposition Shorter Arc L onger Arc More D eposition ARC FOCUS -10.0 (SOFT to 10.0 (STIFF) DESCRIPTION Arc Focus adjusts the arc from a wide, soft arc good for out of position work to a narrow, stiff arc preferred for faster travel speeds. The pulse frequency is lower with a [...]

B-16 OPERA TION B-16 POWER FEED™ 25M ALUMINUM SYNERGIC GMA W -P (PULSED MIG)AND GMA W-PP (PULSE ON PULSE) WELDING The POWER FEED™ 25M and Power Wave welding power source combine to readily produce top quality aluminum welds with excellent appearance, little spat- ter and good bead shape. Push-pull guns are avail- able for consistent feeding whe[...]

B-17 OPERA TION B-17 POWER FEED™ 25M ALUMINUM GMA W -P AND GMA W -PP ALUMINUM PULSE WELDING Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applica- tions. During pulse welding, the welding current continuously switches from a low level to a high level and then back again. Each pulse sends a s[...]

B-18 OPERA TION B-18 POWER FEED™ 25M ALUMINUM GMA W -P AND GMA W -PP WELDING K2368-1 Power Wave ® 355M 1 K2202-1 Power Wave ® 455M K2203-1 Power Wave ® 455M/STT K2230-1 POWER FEED™ 10M, Bench Model Requires K1634-1 Spool cover K2234-1 POWER FEED™ 10M Dual, Bench Model 2 Requires K1634-1 Spool cover K2536-1,-2,-3 POWER FEED™ 25M KP1695-xx[...]

B-19 OPERA TION B-19 POWER FEED™ 25M PULSE PULSE-ON-PULSE FREQUENCY: FREQ.MODULATION (Low)-10.0 to (High)+10.0 (Low)-10.0 to (High)+10.0 DESCRIPTION For Pulse -On-Pulse modes, Arc controls changes the frequ- ency modulation. The freque- -ncy modulation controls the spacing of the ripples in the weld. Use low values for slow travel speeds and wide[...]

B-20 OPERA TION B-20 POWER FEED™ 25M GMA W -STT™ WELDING Surface Tension Transfer , or STT™ weld ing, is a break-through process offered exclusively by the Lincoln Electric Company. STT™ is a low heat, low spatter process created with Waveform Control Technology™. STT™ is the process of choice for open root welding, welding on thin mate[...]

B-21 OPERA TION B-21 GMA W -STT™ Waveform Control Technology™ maximizes the ability to modify the arc for the perfect weld. When STT™ welding, the parameters to control are: • Wire Feed Speed - sets the deposition rate. • Peak Current - controls the arc length. • Background Current - regulates the bead contour. • Tail-out - provides a[...]

B-22 OPERA TION B-22 PEAK CURRENT (Figure B.16) Peak current controls the arc length, which also affects the shape of the root. When using 100% CO 2 , the peak current will be higher than when welding with blended shiel ded gases. A longer arc length is required with CO 2 to reduce spatter. FIGURE B.16 BACKGROUND CURRENT (Figure B.17) Background cu[...]

No Foot / Hand Amptrol 1. Adjust the arc amperage with the left knob on the display panel. 2. Turn the right knob on the display panel until the Output Control is ON. Gas will start to flow. 3. Touch the tungsten to the work piece. 4. Lift the tungsten to create an arc and weld. 5. Stop welding by turning the Output Control to OFF, or by pulling aw[...]

B-24 OPERA TION B-24 POWER FEED™ 25M 8 4 3 2 7 1 5 6 W A R N I N G W A R N I N G A V I S O D E P R E C A U C I O N A T T E N T I O N ! ! ! ! L o r e m i p s u m d o l o r s i t a m e t c o n s e c t e t u e r a d i p i s c i n g L o r e m i p s u m d o l o r s i t a m e t c o n s e c t e t u e r a d i p i s c i n g e l i t , e d d i a m n o n u m[...]

B-25 OPERA TION B-25 POWER FEED™ 25M SET -UP FEA TURES MENU (See Figure B.17b and B.17c for specific Codes) 1. To access the set-up menu, press the Right and Left buttons of the MSP4 panel simultaneously. Note that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The sta- tus LED is not solid green). Change the[...]

B-26 OPERA TION B-26 POWER FEED™ 25M Parameter Definition Exit Setup Menu P .0 This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press the left Mode Select button to exit the setup menu. P .1 Wire Feed Speed Units P.1 selects which units wire feed speed will be displayed in. English = in/minute wire feed speed u[...]

B-27 OPERA TION B-27 POWER FEED™ 25M Parameter Definition P .5 Procedure Change Method Selects how remote procedure selection (A/B) will be made. The selected procedure can be changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods can be used to remotely change the selected procedure: • Use an ex[...]

B-28 OPERA TION B-28 POWER FEED™ 25M Parameter Definition P .7 Gun Offset Adjustment Range: -30 to 30 (default = 0) Adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only be performed when other possible corrections do not solve any push-pull feeding problems. An rpm meter is required to perform the pull gu[...]

B-29 OPERA TION B-29 POWER FEED™ 25M Parameter Definition P .16 Push-Pull Gun Knob Behavior Determines how the potentiometer on the Push/Pull torch will behave. • Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the push-pull gun (default). The left front panel knob is only used to adjust Start and Crat[...]

B-30 OPERA TION B-30 POWER FEED™ 25M Parameter Definition P .103 V iew Software V ersion Information Used for viewing the firmware versions for each board in the system. Press the right MSP Button to enter the option. Rotate Set knob to select the desired board to read. Press the right button again to read the firmware version. Press the left but[...]

B-31 OPERA TION B-31 POWER FEED™ 25M Parameter Definition P .503 Memory Button Disable Disables the specified memory button(s). When a memory is disabled, welding procedures can- not be restored from or saved to that memory. If an attempt is made to save or restore a dis- abled memory, a message will be displayed on the Mode Select Panel indicati[...]

B-32 OPERA TION B-32 POWER FEED™ 25M Parameter Definition P .507 UI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parame- ters. Presently, this option does not exist in any setup menu. P .509 UI Master Lockout Locks all user interface controls, preventing the operator from making any chang[...]

B-33 OPERA TION B-33 POWER FEED™ 25M USER MEMORIES Recall a memory with memory buttons To recall a user a memory, press one of the six user memory buttons. The memory is recalled when the button is released. Do not hold the button for more than two seconds when recalling a user memory. Recall a memory with the gun trigger If desired, memories 2 t[...]

To set limits, press the desired memory button 1-6 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the MSP4 displays "Memory X Set Limits" as shown below. MSP4 DISPLAY B-34 OPERA TION B-34 LIMITS Limits allow the welder to adjust the welding proce- dure only within a defined range. Each user memo[...]

B-35 OPERA TION B-35 POWER FEED™ 25M If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application or Palm O.S. application is required to change the passcode If the passcode has been set to zero (0000), SETUP will illuminate on the MSP4 panel and the display will show the foll[...]

B-36 OPERA TION B-36 POWER FEED™ 25M USER MEMORIES Recall a memory with memory buttons To recall a user a memory, press one of the six user memory buttons. The memory is recalled when the button is released. Do not hold the button for more than two seconds when recalling a user memory. Recall a memory with the gun trigger If desired, memories 2 t[...]

B-37 OPERA TION B-37 POWER FEED™ 25M LIMITS Limits allow the welder to adjust the welding proce- dure only within a defined range. Each user memory may have a different set of limits. For example, memory 1 can be set to limit the WFS to 200 through 300 in/min, and memory 2 can be set to limit the WFS to 275 through 310 in/min, while memo- ry 3 ma[...]

B-38 OPERA TION B-38 POWER FEED™ 25M If the passcode does not equal zero (0000), enter the passcode now. If the passcode has been forgotten, a p.c. computer application or Palm O.S. application is required to change the passcode If the passcode has been set to zero (0000), SETUP will illuminate on the MSP4 panel and the display will show the foll[...]

B-39 OPERA TION B-39 INTERNAL CONTROLS (FOR CODE 11312) POWER FEED™ 25M 2 - S T E P 4 S T E P 1 2 Step / 4 Step T rigger Switch 2 Cold Feed / Purge Switch 3 Wire Drive Pressure Arm 4 Internal Light Switch 5 Internal Heater Switch 6 Spindle Brake 7 Gun Bushing ITEM DESCRIPTION 1 9 8 7 6 3 2 8 Thumb Screw for securi[...]

B-40 OPERA TION B-40 POWER FEED™ 25M INTERNAL CONTROLS (FOR CODE 11456 and higher) 1 Cold Feed / Purge Switch 2 Wire Drive Pressure Arm 3 Internal Light Switch 4 Internal Heater Switch 5 Spindle Brake 6 Gun Bushing ITEM DESCRIPTION 1 8 7 6 3 2 7 Thumb Screw for securing the welding Gun 8 Socket Head Cap Screw for securing the Gun Bushing 4 5[...]

B-41 OPERA TION B-41 COLD FEED/GAS PURGE SWITCH Cold Feed and Gas Purge are com- bined into a single spring centered tog- gle switch. To activate Cold Feeding, hold the switch in the UP position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. Adjust the speed of cold feeding by rotating the W[...]

B-42 OPERA TION B-42 POWER FEED™ 25M 2 STEP - 4 STEP - TRIGGER OPERA TION (For Code 11313) The 2 Step - 4 Step switch changes the function of the gun trigger. 2 Step trigger operation switches the welding output ON-OFF in direct response to the trigger. 4 Step trigger operation provides 't rigger interlock' capability and give s the abi[...]

B-43 OPERA TION B-43 EXAMPLE 1 - 2 STEP TRIGGER: Simple operation The simplest trigger operation occurs with a 2 Step trigger and the Start, Crater and Burnback functions all set to OFF. (See Figure B.19) For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled. RUN-IN: After preflow time expires, the powe[...]

B-44 OPERA TION B-44 POWER FEED™ 25M EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start and Arc End. Tailoring the arc start and arc end is a common method for reducing spatter and improving weld quality. This can be accomplished with the Start and Burnback functions set to a desired values and Crater set to OFF. (See Figure B.20) For this sequence, [...]

B-45 OPERA TION B-45 POWER FEED™ 25M WELD: After upslope, the power source output and the wire feed speed continue at the weld settings. CRATER: As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater time. The time period of ramping from the weld settings to the crater set[...]

B-46 OPERA TION B-46 POWER FEED™ 25M Shield in g Ga s I d le Pre f l o w St ri ke W e l d B ur nb ack P os t f low I dl e WFS On Of f Ru n- in Of f We l d Of f We l d Arc Established T rigger Pulled T rigger Released 4 St ep T rigg e r St art = O F F C rater = OFF B u rnb ack = OF F 1. 5 s e c m a x . St a rt C r at er Po w er So u rce Ou tp ut C[...]

B-47 OPERA TION B-47 POWER FEED™ 25M EXAMPLE 5 - 4 STEP TRIGGER: Manual control of Start and Crater times with Burnback ON. The 4 step trigger sequence gives the most flexibility when the Start, Crater and Burnback functions are active. This is a popular choice when welding aluminum because extra heat may be needed during Start and less heat desi[...]

B-48 OPERA TION B-48 REAR CONTROLS: POWER FEED™ 25M 1 Flow Meter 2 Shielding Gas Inlet 3 5-Pin Arclink Cable Connector 4 Electrode Cable 5 Cover for Optional W ater Line Connector ITEM DESCRIPTION 1 2 3 4 5[...]

B-49 OPERA TION B-49 FLOW METER The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow. The flow meter is scaled for CO 2 , Ar, and CO 2 /Ar blends. It is not cali- brated and is for reference purposes only. The middle of the ball indicates the flow rate of shielding gas. Adjust the flow rate while depressing the GAS [...]

C-1 ACCESSORIES C-1 POWER FEED™ 25M WIRE TYPE Steel Wires: Cored Wires: Aluminum Wires: ELECTRODE SIZE .023-.030 (0.6-0.8mm) .035 (0.9mm) .045 (1.2mm) .052 (1.4mm) 1/16 (1.6mm) .035,.045 (0.9, 1.2mm) .040 (1.0mm) .030-.035" (0.8-0.9mm) .040-.045" (1.0-1.2mm) .052" (1.4mm) 1/16" (1.6mm) .068-.072" (1.7-1.8mm) 5/64" (2[...]

C-2 ACCESSORIES C-2 POWER FEED™ 25M K2429-1 K857 K857-1 K2596-1 K2596-2 K2593-xx K1796-xx K1803-1 K1840-xx K1842-xx ArcLink "T" Cable Adapter Remote Output Control Remote Output Control Aluminum Case Plastic Case #1 Co-Axial Power Cable 1/0 Co-Axial Power Cable Work and Feeder Cables Package Weld Power Cable, Twist-Mate to Lug Weld Powe[...]

C-3 ACCESSORIES C-3 POWER FEED™ 25M K1543-xx K2683-xx K910-1 K910-2 K1500-1 K1500-2 K1500-3 K1500-4 Digital Control Cable Heavy Duty ArcLink Control Cable Ground Clamp Ground Clamp Gun Receiver Bushing (for guns with K466-1 Lincoln gun connec- tors; Innershield ® and Subarc guns) Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun co[...]

C-4 ACCESSORIES C-4 POWER FEED™ 25M K1500-5 K489-7 K2339-1 K590-6 K435 K468 K659-1 3000290 K586-1 Gun Receiver Bushing (compatible with Oxo® guns.) Gun Receiver Bushing (for Lincoln Fast-Mate guns.) Push-Pull Gun Connection Kit Water Connection Kit Spindle Adapter, for mounting 14 lb. (6.4 kg) Innershield Coils on 2 in (51 mm) spindles. Spindle [...]

C-5 ACCESSORIES C-5 POWER FEED™ 25M INST ALLA TION OF THE K590-6 W A TER COOLING KIT ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment. -------------------------------[...]

C-6 ACCESSORIES C-6 W A TER COOLED GUNS ELECTRIC SHOCK can kill. • Turn the input power OFF at the dis- connect switch before working on this equipment. • Do not touch electrically hot parts. • Only qualified personnel should install, use or service this equipment. ------------------------------------------------------------------------ Pytho[...]

D-1 MAINTENANCE D-1 POWER FEED™ 25M ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the weld ing power source off at the fuse box before working in the terminal strip. • Only qualified personnel should [...]

E-1 TROUBLESHOOTING E-1 POWER FEED™ 25M If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repai[...]

E-2 TROUBLESHOOTING E-2 POWER FEED™ 25M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

E-3 TROUBLESHOOTING E-3 POWER FEED™ 25M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

E-4 TROUBLESHOOTING E-4 POWER FEED™ 25M Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBL[...]

F-1 DIAGRAMS F-1 POWER FEED™ 25M - + PO WER AR CLINC RE CEPT ACLE A B C D E 541 L6 540B 540A 640A BRIDG E RECTIFIER 554 AC AC RED / GREE N STATU S LED A P4 532 TRIGGE R CONN ECTOR L3 P10 S1 570G W B 2 3 1 581 585B 582 VOLTA GE / TRI M EN CODE R 2 3 1 587 585A 580 CURR ENT / WFS ENCO DER P1 P2 5 6 7 3 4 2 8 9 10 1 MEMORY P.C. BOARD 5 6 7 3 4 2 8 9[...]

F-2 DIAGRAMS F-2 POWER FEED™ 25M NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code n[...]

F-3 DIMENSION PRINT F-3 POWER FEED™ 25M 14.0 16.9 23.3 8.5 5.4 16.9 14.5 16" Circle 12" x 18" Ellipse Dimensions for Code 11313[...]

F-4 DIMENSION PRINT F-4 POWER FEED™ 25M 14.0 16.9 23.3 8.5 5.4 16.9 14.5 16" Circle 12" x 18" Ellipse Dimensions for Codes 11456, 11557[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out o f fumes . ● Use ventil atio n or e xhaust to remo ve fu[...]

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